Interchangeable handguard system

ABSTRACT

A handguard assembly includes a first handguard including an interior surface and an exterior surface. The interior surface faces toward an associated barrel of an associated firearm and the exterior surface faces away from the associated barrel. The first handguard extends between a breech end of the first handguard and a muzzle end of the first handguard so as to define a longitudinal axis and a first handguard length. The handguard assembly also includes an adapter radially surrounding an associated barrel nut along the longitudinal axis. The adapter is longitudinally disposed between the first handguard and an associated receiver of the associated firearm.

BACKGROUND

Handguards are utilized on many types of firearms for a variety of reasons. For example, handguard can provide for an improved grip for the user of the firearm. Further, the handguard also provides protection to the user, by isolating some of the heat that can be generated by a barrel during operation of the firearm.

Handguards are typically directly connected to a barrel nut for connection to a receiver of the firearm and the handguard is of a fixed length. Users of firearms sometimes desire to customize their firearm for performance or aesthetic reasons. These changes could include changing the barrel, which could result in the barrel length being changed.

Alternatively, the user may wish to replace the flash suppressor (a.k.a. flash guard, flash eliminator, flash hider, or flash cone) with a sound suppressor (a.k.a. silencer). Either of these changes can result in an overall length of the firearm being changed. As another example, the user may wish to have a firearm with different amount of coverage (i.e., length) of the barrel received within the handguard. This could be for aesthetic or performance related reason. However, to effectuate this change, the user must purchase a new handguard that has a different length. As will be appreciated, this is not desired.

Also, many handguards are not sufficiently sized so as to allow a sound suppressor to be received therein. Of the handguards that are sufficiently sized so as to allow receipt of a sound suppressor, their overall size and one-piece design is not aesthetically pleasing, nor is it convenient for installation of the sound suppressor or subsequent operation of the firearm.

In view of the above difficulties, a better handguard assembly is needed.

SUMMARY

In view of the foregoing, a handguard assembly includes a first handguard including an interior surface and an exterior surface. The interior surface faces toward an associated barrel of an associated firearm and the exterior surface faces away from the associated barrel. The first handguard extends between a breech end of the first handguard and a muzzle end of the first handguard so as to define a longitudinal axis and a first handguard length. The handguard assembly also includes an adapter radially surrounding an associated barrel nut along the longitudinal axis. The adapter is longitudinally disposed between the first handguard and an associated receiver of the associated firearm.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an elevation view of a firearm with a handguard assembly.

FIG. 1B is an elevation view of the firearm with the handguard assembly.

FIG. 1C is an elevation view of the firearm with the handguard assembly.

FIG. 2 is an exploded perspective view of three handguards of the handguard assembly.

FIG. 3 is a section view of FIG. 2.

DETAILED DESCRIPTION

It should, of course, be understood that the description and drawings herein are merely illustrative and that various modifications and changes can be made in the structures disclosed without departing from the present disclosure. Referring now to the drawings, wherein like numerals refer to like parts throughout the several views, FIGS. 1A-1C schematically depict a firearm 10 according to the present disclosure.

The term “firearm” is used to denote any type of weapon that discharges projectiles. It will be appreciated that the firearm 10 could be any number of configurations without departing from the scope of this disclosure. As illustrated, the firearm 10 is a semi-automatic rifle that can be magazine fed. The basic operation of the firearm 10 is well understood, and a detailed explanation thereof is not necessary for an understanding of the present invention.

The firearm 10 generally includes a handguard assembly 12, a stock 14, a barrel 16, and a receiver 18. The stock 14 is disposed at a rear end of the firearm and the barrel 16 is disposed at a front end of the firearm 10, with the receiver 18 disposed therebetween. It is noted that the firearms depicted in FIGS. 1A-1C are identical to one another but for the presence of different handguards as will be described in more detail hereinafter.

With reference to FIG. 2, the handguard assembly 12 is shown in exploded view. The handguard assembly 12 can include a key fastener 20, a first handguard 22, a second handguard 24, a third handguard 26, an adapter 28, a key 30, and a barrel nut 32. Initially, it is noted that the first handguard 22, the second handguard 24, and the third handguard 26 can be identical to one another in all regards, but for having different lengths from one another.

In the interest of brevity, all portions, elements, and features of the first handguard 22, the second handguard 24, and the third handguard 26 described hereinafter are identical unless specifically noted. Further, the first handguard 22, the second handguard 24, and the third handguard 26 can be made from a plurality of materials without departing from the scope of this disclosure. Additionally, the first handguard 22, the second handguard 24, and the third handguard 26 can be generally circular in cross-section and define a hollow portion for receipt of various components as will be described in more detail hereinafter.

With reference to FIGS. 1A, 2, and 3, the first handguard 22 includes an interior surface 34 and an exterior surface 36. The interior surface 34 faces toward the barrel 16 of the firearm 10 and the exterior surface 36 faces away from the barrel 16. The first handguard defines a barrel passage 38 to allow for at least partial receipt of the barrel 16 of the firearm 10.

Further, the first handguard 22 extends between a breech end 42 of the first handguard 22 and a muzzle end 44 of the first handguard 22 so as to define a longitudinal axis 46 and a first handguard length. As illustrated in FIG. 1A, the first handguard 22 is sized so as to allow a connection between a muzzle device 48 and the barrel 16 within the first handguard 22. The muzzle device 48 can be a sound suppressor.

The first handguard 22 can also define a first handguard inner diameter 52 and a first handguard 22 outer diameter. With reference to FIGS. 2 and 3, the first handguard inner diameter 52 and the first handguard outer diameter 54 remain constant along an entirety of the first handguard length. As shown in FIG. 2, the breech end 42 of the first handguard 22 can define at least one mounting hole 56 that extends between the interior surface 34 and the exterior surface 36 to provide fluid communication therethrough for receipt of least one fastener 84 to threadingly engage the adapter 28 as will be described hereinafter. Further, the exterior surface 36 of the first handguard 22 is spaced from the longitudinal axis 46 to define a first handguard radius.

With reference to FIGS. 1B, 2, and 3, the second handguard 24 extends between a breech end 58 of the second handguard 24 and a muzzle end 62 of the second handguard 24 so as to define a second handguard length. As illustrated, the second handguard length is less than the first handguard length. As such, the muzzle device 48 extends past the muzzle end 62 so as to exit the second handguard 24. The second handguard 24 defines a second handguard inner diameter 64 and a second handguard outer diameter 66.

With reference to FIGS. 2-3, the first handguard outer diameter 54 and the second handguard outer diameter 66 are equal to one another. Further, the first handguard inner diameter 52 and the second handguard 24 inner diameter can be equal to one another. As such, the user of the firearm can switch attachment between the adapter 28 and first handguard 22 or the second handguard 24 (or the third handguard 26 as will be described hereinafter) without purchasing additional components.

With attention to FIGS. 1C, 2, and 3, the third handguard 26 extends between a breech end 68 of the third handguard 26 and a muzzle end 72 of the third handguard 26 so as to define a third handguard length. Further, the third handguard 26 defines a third handguard inner diameter 74 and a third handguard outer diameter 76.

As illustrated, the third handguard length is greater than the second handguard length. However, the third handguard outer diameter 76 and the second handguard outer diameter 66 are equal to one another and the third handguard inner diameter 74 and the second handguard 24 inner diameter are equal to one another. As noted hereinbefore, this same inner diameter between the handguards allows for easy interchangeability for the user of the firearm 10.

The adapter 28 is shown in FIGS. 1A-1C, 2, and 3. The adapter 28 radially surrounds the barrel nut 32 along the longitudinal axis 46. As shown in FIG. 1A, the adapter 28 is longitudinally disposed between the first handguard 22 and the receiver 18 of the firearm 10. Alternatively, as shown in FIGS. 1B and 1C, when the first handguard 22 is replaced with either the second handguard 24 or the third handguard 26, the adapter 28 is longitudinally disposed between the receiver 18 of the firearm 10 and either the second handguard 24 or the third handguard 26, respectively.

It is also noted that the adapter 28 can be at least partially and selectively received in either the first handguard 22, the second handguard 24, or the third handguard 26. Further, the adapter 28 is separable from the first handguard 22, the second handguard 24, the third handguard 26, and the barrel nut 32. Finally, the adapter 28 can be at least partially and selectively received in the second handguard 24 or the third handguard 26 instead of being partially and selectively received in the first handguard 22.

With reference to FIGS. 2-3, the adapter 28 can include a mounting ring 78 and a hub 80. The mounting ring 78 is configured to be individually and slidably received within the first handguard 22, the second handguard 24, and the third handguard 26. The mounting ring 78 of the adapter 28 can define at least one mounting bore 82 that allows for passage of at least one fastener 84 to threadingly engage the first handguard 22.

As illustrated, the adapter 28 includes three mounting bores 82 radially disposed at the 3 o'clock, 6 o'clock, and 9 o'clock position. As such, the at least one mounting hole 56 that is present on the first handguard 22, the second handguard 24, and the third handguard 26 and the at least one mounting bore 82 of the adapter 28 can be in selective registry with one another. This provides for a secure connection between the adapter 28 and either the first handguard 22, the second handguard 24, or the third handguard 26.

The mounting ring 78 of the adapter 28 defines a mounting ring inner diameter 86. The mounting ring inner diameter 86 is individually less than the first handguard outer diameter 54, the second handguard outer diameter 66, or the third handguard outer diameter 76. The mounting ring 78 also defines a mounting ring outer diameter 88.

As illustrated, the mounting ring inner diameter 86 and the mounting ring outer diameter 88 can be constant along an entirety of a longitudinal length of the mounting ring 78. The mounting ring outer diameter 88, which can also be referred to as the mounting ring exterior surface, is radially spaced from the longitudinal axis 46 so as to define a mounting ring radius. It is noted that a radius of the first handguard 22 can be greater than the mounting ring radius.

As previously indicated, the adapter 28 can include the hub 80. The hub 80 is not received within the first handguard 22, the second handguard 24, or the third handguard 26 when the handguard assembly 12 is installed on the receiver 18 of the firearm 10. However, the hub 80 is longitudinally disposed between the mounting ring 78 and the receiver 18 of the firearm 10. As illustrated, the adapter 28 defines a barrel tunnel 94 that allows the barrel 16 to extend therethrough. The at least one mounting hole 56 of the first handguard 22 and the at least one mounting bore 82 of the adapter 28 cooperate to allow fluid communication with the barrel passage 38 and the barrel tunnel 94.

The hub 80 can also include a hub inner diameter 96 and a hub outer diameter 98. The hub outer diameter 98 is greater than the mounting ring outer diameter 88. The hub 80 can also include a hub exterior surface 102. The mounting ring exterior surface is spaced from the longitudinal axis 46 a distance that is less than a distance that the hub exterior surface 102 is spaced from the longitudinal axis 46. Additionally, the hub 80 of the adapter 28 can include a key receiving recess 104 that slidably receives the key 30.

The key 30 can engage the barrel nut 32 when the barrel nut 32 is received in the hub 80 of the adapter 28. Additionally, the key 30 can be received in the key receiving recess 104. By receiving the key 30 in the key receiving recess 104 of the adapter, longitudinal movement of the adapter 28 with respect to the barrel nut 32 is prevented. To further improve the connection of either the first handguard 22, the second handguard 24, or the third handguard 26 to the receiver 18 of the firearm, the barrel nut 32 can be threadingly connected to the receiver 18 of the firearm 10.

With continued reference to FIG. 2, the barrel nut 32 is shown. The barrel nut 32 can have a cylindrical outer shape and defines an inner diameter and an outer diameter. The inner diameter of the barrel nut 32 allows for passage of the barrel 16 of the firearm 10 and the outer diameter is at least partially received in the adapter 28. The barrel nut 32 may be made from any number of materials without departing from the scope of this disclosure. The barrel nut 32 merely needs to be made of a material of sufficient strength to provide a sturdy interface between the receiver 18 and the adapter 28.

The barrel nut 32 can include at least one projection receiving portion. As illustrated, there are a plurality of projection receiving portions 32 a, 32 b depicted as a pair of circumferential grooves that are longitudinally spaced from one another to extend about the outer diameter of the barrel nut 32 without entirely extending from the outer diameter to the inner diameter. Stated another way, the at least one projection receiving portion is circumferentially disposed about the outer diameter of the barrel nut 32. The projection receiving portions 32 a, 32 b can receive the key 30.

The adapter 28 can also include a first ear 40 and a second ear 50. The first ear 40 and the second ear 50 can cooperate to define a slot 60 that extends in the longitudinal direction. The slot 60 separates the first ear 40 and the second ear 50 and allows the hub inner diameter 96 to be modified so as to ensure a secure connection between the adapter 28 and the barrel nut 32.

The key 30 can be made of similar or different materials than the barrel nut 32 and the adapter 28. The key 30 can include a main body 30 a that can have a generally rectangular shape. The key receiving recess 104 of the adapter 28 slidably receives the main body 30 a of the key 30. This coplanar arrangement provides ease of use for the user of the firearm 10. The key 30 can also include a first projection 30 b and a second projection 30 c that extend from the main body 30 a in a same direction.

When the barrel nut 32 and the key 30 are received in the adapter 28, the at least one of the projection receiving portions 32 a, 32 b of the barrel nut 32 can slidably receive and engage at least one of the first projection 30 b and the second projection 30 c. As such, the adapter 28 is configured to receive the key 30 with the first and second projections 30 b, 30 c for engagement with the barrel nut 32. It is noted that by having the first projection 30 b and the second projection 30 c, that the strength of the connection between the adapter 28 and the barrel nut 32, and hence, the handguard assembly 12, is enhanced.

The handguard assembly 12 can also include the key fastener 20. As illustrated, there are a plurality of key fasteners 20. It will be understood that any number of key fasteners 20 could be utilized without departing from the scope of this disclosure. By utilizing a plurality of fasteners, the connection between the key 30, the adapter 28, and the barrel nut 32 can be ensured.

In view of FIGS. 1A-1C, 2, and 3, installation of the handguard assembly 12 onto the firearm 10 will now be described. Initially, a breech end of the barrel 16 can be at least partially inserted into the receiver 18. Then, the barrel nut 32 is slid over the muzzle end of the barrel 16 to the receiver 18 and then can be threaded onto the receiver 18 of the firearm 10.

Next, the adapter 28, being devoid of the key 30, can be installed so as to receive the barrel 16 such that the hub 80 of the adapter 28 is near the receiver 18 and the mounting ring 78 of the adapter 28 is near the muzzle end of the barrel 16. Thus, the adapter 28 at least partially surrounds at least part of the barrel nut 32 in a circumferential manner. Once the adapter 28 is oriented in this manner, the key 30 may be inserted in the key receiving recess 104 of the adapter 28 and the key fastener 20 can engage the key 30 to securely connect the adapter 28 to the barrel nut 32, and hence the receiver 18 of the firearm 10.

Next, the sound suppressor 48 may be connected to the barrel 16. However, installation of the sound suppressor 48 is not required. Rather, a flash suppressor or no component whatsoever could be installed onto the barrel 16 without departing from the scope of this disclosure. Since the sound suppressor 48 can be attached to the barrel 16 before either the first handguard 22, the second handguard 24, or the third handguard 26 is installed on the firearm 10, the user can easily view the connection between the barrel 16 and the sound suppressor 48. As will be appreciated, this reduces the likelihood of improper installation of the sound suppressor 48. Next, the first handguard 22, the second handguard 24, or the third handguard 26 can be at least partially placed over the barrel 16 and connected to the adapter 28.

Thus, the user of the firearm 10 can adjust the length of the handguard with minimal effort by merely changing the handguard 22, 24, 26 with the barrel nut 32 and the adapter 28 remaining installed on the firearm 10. The at least one mounting hole 56 of the first handguard 22, the second handguard 24, or the third handguard 26 can then be aligned with the at least one mounting bore 82 of the adapter 28 and the at least one fastener 84 can be passed through the at least one mounting hole 56 of the first handguard 22, the second handguard 24, or the third handguard 26 to engage the at least one mounting bore 82 of the adapter 28 to ensure a secure connection between the handguard and the adapter 28.

As shown in the figures, numerous advantages are provided by the handguard assembly 12 as compared to traditional handguard assemblies. For example, weight savings are realized with the present handguard assembly 12. The reason for this is that the first handguard 22, the second handguard 24, or the third handguard 26 can be made of a thinner material as the connection that receives the majority of the resistive forces is the adapter 28. As will be appreciated, it is desirable to reduce the weight of the firearm 10 for user convenience when the firearm 10 is being carried for long distances or times.

Further, the adapter 28 and the first handguard 22, the second handguard 24, and the third handguard 26 share a common reduced outer diameter profile. As compared to traditional handguards that are sized to receive a sound suppressor, this reduced outer diameter profile of the present handguard assembly 12 also provides and enhanced user experience. For example, this lower profile allows the user to have a better line of sight along the top of handguard assembly 12 that is closer to the true ballistic path of the bullet when it leaves the barrel 16. The lower profile also provides an improved aesthetic appearance for the firearm 10.

A handguard assembly has been described above in particularity. Modifications and alternations will occur to those upon reading and understanding the preceding detail description. The invention, however, is not limited to only the embodiment described above. Instead, the invention is broadly defined by the appended claims and the equivalents thereof. 

1. A handguard assembly, comprising: a first handguard including an interior surface and an exterior surface, the interior surface facing toward an associated barrel of an associated firearm and the exterior surface facing away from the associated barrel, the first handguard extending between a breech end of the first handguard and a muzzle end of the first handguard so as to define a longitudinal axis and a first handguard length; and an adapter radially surrounding an associated barrel nut along the longitudinal axis, wherein the adapter is longitudinally disposed between the first handguard and an associated receiver of the associated firearm.
 2. The handguard assembly of claim 1, wherein the adapter is at least partially and selectively received in the first handguard.
 3. The handguard assembly of claim 1, wherein the adapter is separable from the first handguard and from the associated barrel nut.
 4. The handguard assembly of claim 1, where the adapter includes a mounting ring that is received within the first handguard and a hub that is not received within the first handguard, and wherein the hub is longitudinally disposed between the mounting ring and the associated receiver of the associated firearm.
 5. The handguard assembly of claim 4, wherein the mounting ring defines a mounting ring exterior surface and the hub defines a hub exterior surface, and wherein the mounting ring exterior surface is spaced from the longitudinal axis a distance that is less than a distance that the hub exterior surface is spaced from the longitudinal axis.
 6. The handguard assembly of claim 4, wherein the mounting ring of the adapter defines a mounting ring exterior surface that is radially spaced from the longitudinal axis so as to define a mounting ring radius and the exterior surface of the first handguard is spaced from the longitudinal axis to define a first handguard radius, and wherein the first handguard radius is greater than the mounting ring radius.
 7. The handguard assembly of claim 4, wherein the mounting ring of the adapter defines a mounting ring inner diameter and a mounting ring outer diameter, the mounting ring inner diameter and the mounting ring outer diameter being constant along an entirety of a longitudinal length of the mounting ring, wherein the hub of the adapter defines a hub outer diameter and a hub inner diameter, and wherein the hub outer diameter is greater than the mounting ring outer diameter.
 8. The handguard assembly of claim 7, wherein the hub inner diameter is equal to the mounting ring inner diameter.
 9. The handguard assembly of claim 4, wherein the hub of the adapter defines a key receiving recess that slidably receives a key that prevents longitudinal movement of the adapter with respect to the associated barrel nut, and wherein the mounting ring of the adapter defines at least one mounting bore that allows for passage of at least one fastener to threadingly engage the first handguard.
 10. The handguard assembly of claim 1, further comprising a second handguard that extends between a breech end of the second handguard and a muzzle end of the second handguard so as to define a second handguard length, wherein the second handguard length is less than the first handguard length.
 11. The handguard assembly of claim 10, wherein the adapter is at least partially and selectively received in the second handguard instead of being partially and selectively received in the first handguard.
 12. The handguard assembly of claim 10, wherein the first handguard defines a first handguard inner diameter and a first handguard outer diameter, wherein the first handguard inner diameter and the first handguard outer diameter remain constant along an entirety of the first handguard length.
 13. The handguard assembly of claim 12, wherein the second handguard defines a second handguard inner diameter and a second handguard outer diameter, wherein the second handguard inner diameter and the second handguard outer diameter remain constant along an entirety of the second handguard length so as to receive the adapter, and wherein the second handguard inner diameter is equal to the first handguard inner diameter.
 14. The handguard assembly of claim 13, further comprising: a third handguard extending between a breech end of the third handguard and a muzzle end of the third handguard so as to define a third handguard length, wherein the third handguard defines a third handguard inner diameter and a third handguard outer diameter, wherein the third handguard length is less than the second handguard length, wherein the third handguard outer diameter and the second handguard outer diameter are equal to one another, and wherein the third handguard inner diameter and the second handguard inner diameter are equal to one another.
 15. The handguard assembly of claim 1, wherein the breech end of the first handguard defines at least one mounting hole, wherein the adapter includes a mounting ring that is received within the first handguard and a hub that is not received within the first handguard, and wherein the mounting ring defines at least one mounting bore that radially extends through the mounting ring, and wherein the at least one mounting hole of the first handguard and the at least one mounting bore of the adapter are in selective registry with one another.
 16. The handguard assembly of claim 15, wherein the first handguard defines a barrel passage to allow for at least partial receipt of the associated barrel of the associated firearm and the adapter defines a barrel tunnel that allows the associated barrel to extend therethrough, and wherein the at least one mounting hole of the first handguard and the at least one mounting bore of the adapter cooperate to allow fluid communication with the barrel passage and the barrel tunnel.
 17. The handguard assembly of claim 1, wherein the first handguard is sized so as to allow a connection between an associated muzzle device and the associated barrel within the first handguard.
 18. The handguard assembly of claim 17, wherein the associated muzzle device is a sound suppressor.
 19. The handguard assembly of claim 1, further comprising: a key that engages the associated barrel nut that is threadingly connected to the associated receiver of the associated firearm, wherein the adapter defines a key receiving recess that slidably receives the key, and wherein the key is received in the key receiving recess so as to prevent longitudinal movement of the adapter with respect to the associated barrel nut.
 20. The handguard assembly of claim 19, wherein the key includes a main body from which a first projection and a second projection extend in a same direction from the main body, and wherein the adapter is configured to receive the key with the first and second projections for engagement with the associated barrel nut. 